Method and apparatus for attaching insert panels to carton blanks

Abstract

An apparatus for attaching insert panels to carton blanks including: a carton blank conveyor for moving carton blanks along a predetermined displacement path; a carton blank folder positioned at a fixed station along the displacement path for folding an end panel portion of each passing carton blank for providing an abutment surface for engaging a carton insert panel; an insert panel applicator positioned at a fixed station along the displacement path for applying an insert panel to each passing carton blank; a registration assembly for urging a predetermined edge portion of each insert panel into abutment with the abutment surface on each folded carton blank.

What is claimed is: 
     
       1. An apparatus for attaching insert panels to carton blanks comprising: carton blank conveyor means for moving carton blanks along a predetermined displacement path;   carton blank folder means positioned at a fixed station along said displacement path for folding an end panel portion of each passing carton blank for providing an abutment surface for engaging an insert panel;   insert panel applicator means positioned at a fixed station along said displacement path for applying an insert panel to each passing carton blank;   registration means for urging a predetermined edge portion of each insert panel into abutment with said abutment surface on each folded carton blank.   
     
     
       2. The invention of claim 1 further comprising attachment means for fixedly attaching each insert panel to an associated carton blank wherein said attachment means comprises adhesive applicator means for applying adhesive to at least one of said carton blanks or said insert panels. 
     
     
       3. The invention of claim 1 further comprising attachment means for fixedly attaching each insert panel to an associated carton blank wherein said attachment means comprises compression means for compressing each carton blank and associated insert panel in the region of said adhesive. 
     
     
       4. The invention of claim 1 wherein said folder means comprises means for folding a trailing edge end panel portion of each carton blank. 
     
     
       5. The invention of claim 4 wherein each folder means folds said carton trailing edge panel upwardly and forwardly. 
     
     
       6. The invention of claim 1 further comprising hold down means positioned along said carton blank displacement path for holding each said end panel folded by said folder means in overlying relationship with the remainder of an associated carton blank for a predetermined distance of carton blank displacement along said displacement path. 
     
     
       7. The invention of claim 6 wherein said hold down means comprises a fixed rail positioned above said carton blank conveyor means. 
     
     
       8. The invention of claim 6 wherein said hold down means comprises a moving belt positioned above said carton blank conveyor means. 
     
     
       9. The invention of claim 8 wherein said moving belt means comprises a portion of said insert panel applicator means. 
     
     
       10. The invention of claim 1 wherein said registration means comprises drag means for applying a drag force to each said insert panel subsequent to its application to a carton blank for retarding the motion of said insert panel relative to the motion of said carton blank for urging said insert panel rearwardly into engagement with said abutment surface of said carton blank. 
     
     
       11. The invention of claim 1 further comprising carton blank detection means positioned along said displacement path upstream from said insert panel applicator means for detecting the passage of a carton blank and for generating a detection signal in response thereto and wherein said insert applicator means is actuated in response to said detection signal. 
     
     
       12. An apparatus for attaching insert panels of the type each having a top surface, a bottom surface, a leading edge portion and a trailing edge portion to carton blanks of the type each having a top surface, a bottom surface and a plurality of score lines defining a set of sidewall panels, a first set of end panels attached at first ends of said sidewall panels and defining a leading edge portion of said carton blank and a second set of end panels attached at second ends of said sidewall panels and defining a trailing edge portion of said carton blank, comprising: carton blank single feeder means for feeding said carton blanks, one at a time, to a carton blank conveyor means;   carton blank conveyor means for conveying carton blanks in bottom surface down, leading edge first, spaced apart, single file relationship along a carton blank displacement path;   carton blank lug means affixed at equal interval spacing to said carton blank conveyor means for engaging said trailing edge portion of each carton blank fed to said conveyor means for maintaining a predetermined spacing interval between carton blanks on said carton blank conveyor belt means;   end panel folder means for folding at least one of said second set of end panels about a score line which separates it from an associated sidewall panel such that said folded end panel is positioned in overlying relationship with said associated sidewall panel;   panel hold down means positioned above said carton blank displacement path for maintaining said folded end panel in overlying relationship with said associated sidewall panel along a first predetermined length of said carton blank displacement path;   carton blank sensor means positioned at a fixed sensing station along said displacement path for sensing the passage of a carton blank and for generating a carton blank sensing signal in response thereto;   adhesive applicator means positioned at a fixed location above said displacement path downstream from said sensing station and responsive to said sensor signal for applying adhesive to said top surface of each carton blank at a predetermined region thereof;   insert panel single feeder means responsive to said sensor signal for feeding one of said insert panels to an insert panel conveyor means in response to the detection of a carton blank by said sensor means;   insert panel conveyor means for conveying insert panels in single file relationship along an insert panel displacement path and for depositing each insert panel onto a below passing carton blank moving along said carton blank displacement path, said insert panel conveyor means coacting with said folded end panel of each carton blank subsequent to it disengagement from said first hold down means for maintaining said folded end panel in overlying relationship with said associated sidewall panel until said folded end panel is engaged by a second end panel hold down means;   insert panel lug means affixed at equal interval spacing to said conveyor means for engaging said trailing edge portion of each insert panel fed to said insert panel conveyor means for maintaining a predetermined spacing interval between insert panels on said insert panel conveyor belt means, the movement of said insert panel lug means being timed relative to the movement of said carton blank lug means such that each infed insert panel is deposited on top of a sensed carton blank at a position thereon forward of the forwardmost edge of said folded end panel on said carton blank;   drag means positioned along said carton blank displacement path for applying a retarding force to each insert panel after it leaves said insert panel conveyor means for displacing said insert panel rearwardly relative to a container blank upon which it is deposited for urging said trailing edge portion of said insert panel into abutting relationship with said folded end panel on said container blank;   compression nip means positioned along said carton displacement path downstream of said drag means for applying compressive force to each carton blank and an associated insert panel in said predetermined region where said adhesive has been applied to said carton blank;   second end panel hold down means positioned above said carton blank displacement path for maintaining said folded end panel in overlying relationship with said associated sidewall panel along a second predetermined length of said carton blank displacement path;   whereby each insert panel is adhesively attached to a carton blank with said insert panel trailing edge positioned in registration with a score line which separates a carton blank sidewall panel from an associated second end panel.   
     
     
       13. A method of preparing a plurality of flat carton blanks and flat insert panels for folding and gluing into reinforced carton configurations comprising the steps of: moving the carton blanks along a predetermined displacement path;   deforming each carton blank to provide a surface projecting transversely of the direction of carton displacement;   laying an insert panel on said one flat surface of each carton blank moving along said displacement path;   placing each insert panel in a predetermined registration position with an associated carton blank by urging a predetermined edge portion of each insert panel into abutting relationship with said projecting surface on an associated carton blank;   fixedly attaching each registeringly positioned insert panel to each associated carton blank.   
     
     
       14. The method of claim 13 wherein said step of deforming said carton blank comprises folding an end panel portion of said carton blank. 
     
     
       15. The method of claim 14 wherein said step of placing each insert panel in a predetermined registration position comprises retarding the movement of the insert panel relative to the movement of the associated carton blank. 
     
     
       16. The method of claim 15 wherein the step of fixedly attaching each registeringly positioned insert panel to an associated carton blank comprises the steps of: applying an adhesive agent on said one flat surface of each carton blank prior to laying an insert panel thereon;   subsequent to registration of the insert panel with a carton blank compressing the insert panel and the carton blank between a pair of compression surfaces.   
     
     
       17. The invention of claim 16 comprising the further step of detecting the passage of each carton blank along the carton blank displacement path and performing at least one of the steps of applying an adhesive agent to each carton blank and laying an insert panel on each carton blank in response to the detection of each carton blank.